Storage battery electrode



Dec. 15, 1953 J. B.. BRENNAN 2,662,928

STORAGE BATTERY ELECTRODE Filed Feb. 25, 1950 fie INVEN TOR. 70

ArroeNEYS Patented Dec. 15, 1953 UNITED STATES PATENT OFFICE STORAGE BATTERY ELECTRODE Joseph B. Brennan, Cleveland, Ohio Application February 25, 1950, Serial No. 146,237

\ 8 Claims. 1

This invention relates to an electrode for electrolytic devices, such as for storage batteries.

Insofar as common subject. matter is concerned, this application is a continuation in part of my application Serial No. 591,909, filed May 4, 1945, and now abandoned.

An object of this invention is to provide a more stable porous metal electrode for use in storage .batteries, and the description is particularly directed herein to a negative composite electrode for an alkaline cell.

According to this invention the negative electrodecomprises at least two layers of porous metal-one layer of metal being superimposed on another layer of porous metal, whereby the generally less stable and more active porous metal layer functions electrolytically thru a .membrane comprised of a particulate bonded layer'of more stable porous metal.

According to this invention a layer of for example zinc, cadmium or iron, or silver, is first made into a conductive coherent,preferably thin porous layer, as for example by spray depositing molten particles thereof in strip form, preferably continuously as described in the above mentioned pending applications.

If desired, porous metallic conductive strip may be made by sintering any thin strip or wire form. Parallel metallic filaments and/or fibrous cords or strands may be included in the molten particulate metal layer if desired, according to this invention. This is accomplished by using the parallel strands of metal and/or fibrous cords as a base upon which the particulate molten metal is spray deposited on one or both sides.

After a first porous metallic strip has been made, it may be pasted or electroformed with active material, which is generally an oxide of .the molten particulate metal of whichthis strip iscomposed. Such first strip, according to this invention, is made of, for example, spray deposited zinc, cadmium or iron, or silver, for use in an alkaline cell. Thereafter this first strip of porousmetal may be slit or perforated to increase the porosity thereof, or may be used with thenormally secured porosity as described in the above applications.

The next operation in carrying out my invention is to spray deposit. a molten layer of nickel which is porous, over the initially deposited porous first strip metal layer, so as to form an enclosure therearound which will act as a fine porous filter membrane. Such enclosure will 'retain the active materials in the location in which they are initially formed or placed. This may be accomplished by first continuously spray depositing both sides of the strip of for example, the initial zinc spray deposited strip with nickel while running same or'passing same over a fluid coole cl, highly polished ;non-adherent. roll.

Thereafterthe composite strip may be cut into 2 suitable lengths and have the ends spray deposited with nickel where cut, so that a continuous envelope of porous sprayed deposited nickel extends over the entire body of the porous zinc inner spray deposited layer. g

It is also desirable, for certain applications,to have an outer layer of finely perforated metalto act as a support for the multiple spray deposited layer which can be applied after the inner composite spray deposited layers are made by welding finely perforated sheet metal thereover and therearound to render the electrode structure more rugged. If preferred, the perforated sheet metal may be used as a base for spraying deposited nickel in thin layer form thereover, and thereafter spray depositing a layer of for example, zinc or cadmium or iron, or a mixture of zinc and cadmium,.upon one side of said perforated strip metal, and thereafter taking two cut-out pieces of a so constituted composite layer and placing them in face to facerelation, with the most negative ofthe metals adjacent, and line welding these composite strips together to form a unitary electrode. In either example given the zinc or cadmium, or iron, or silver will be interior to and enclosed by the nickel porous envelope.

Referring to the drawings herewith:

Fig. 1 is a perspective view showing anelectrode embodying the present invention, the electrode being shown mainly in elevation but with portions thereof in section. I e

Fig. 2 is a perspective view similar to that of Fig. l but showing an electrode of a somewhat different form of construction; and a Fig. 3 is a perspective view showing a storage battery utilizing electrodes of the present invention, the battery being shown partially in elevation and partially in vertical section. i I

Figure 1 represents a composite negative. electrode wherein 2 Fig. 1 is a body or layer of spray deposited zinc having zinc active material included therein due to electro-formationlor pasting, and I Fig. 1 represents a porous molten spray deposited conductive coherent, layer of nickel thereover. 3 Fig. 1 represents a perforate sheet metal enclosure, and 4 Fig. 1v the perforations in said sheet metal enclosure. S-Fig. 1 represents line welding whereby the layers of exterior sheet metal are joined together, and 6 Fig. 1

.represents a nickel enclosed terminal member.

Figure 2 of the drawings represents such an electrode without the sheet metal enclosure. 2

Fig. 2 represents the inner layer of-molten zinc spray deposited in finemet'allic form having active material included therein, and lFig. 2 represents the sheath or envelope of molten nickel which has been spray deposited thereover. G Fig.

'2 represents alike terminal to that shown in Figure 1. L v

Figures represents aseries of three electrodes assembled in a, for example, plastic polystyrene bag, 8 Fig. 3, which is sealed completely around these three electrodes and contains suitable electrolyte il i g. 1i, such as a zinc'at' solution,fwlien the composite electrodes, 1 Fig. 3, are of particulate zinc enclosed in porous spray deposited nickel. in Fig. 3 represents a preferably porous nickel electrode impregnated '1 eieetr'erormea with cadmium hydroxide, and l I Fig, 3 represents suitable porous spacers of nonconductiv'e"rii'aterial between these three electrodes.

The principal advantage of this invention resides in the retardationpf treeing, which is; gen er all present in an alkaline cell where for exeieecreaes are in conjunction nicicel electrodes;

It isalso to understood according to this intention that a mixture of and cadmium molten spray deposited particulate r'netal may be used in the inner pci-ticn of each electrode to -promote stability in this inner portion.

meeueaee tor otli'e'r electrolytic devices may be advem'ageeusiy made in two or more 'oraus particulate layer fo'riii'. example, an alumipc'rous' electrode may be enclosed in an envelope of porous tantalum for 'anelectrolytic ediid iiser; and a pereu's' magnesium electrode g a be enclosed in porous envelope or aluminiiin teammate stability and to retard disin- "tegration. The extend! bere s particulate inetalliic -rrier'i bra'iieiii. the mere stable metal acts as an ar'iticorrosiori and a 'stabilizing shield. Iflieamou'rit a: ese ei'ey' in each 'eieetmee can ee mereajsea aavencaeeeu siy by su eessiveiy spray depostiiig'a'number 0! metallic iayere one upon the other; ire. for eian'iple'thr'ee 'sii'eeess ve myers r are iiiay 1b! spiayjdposited; and men sevml mere 61 nickel tiireever. This Will ive "greater eseaeity re"; the 'iiiiiciii'n't "(if "metal used than a single thicker layer "or ena a amine thicker layer of porous nickel thereover.

it is use etiiitt-inphitea aeeerairig' as this inve 'u mpa simiitaiieeusiyseiay deposit exteriorly iiibit'eii' ei'tibfiiiit iiiet'aijiir Widely airrerent par- 'tleie size as as as *tdfn'i a spray 'tl'epo site'd grid by means of exteriorlymitrilargeparticles thea ers i'o release; and filling iii this grid bysiiiiiyiii'g ekt'eiidrly 'melten particl esof 1 /2 tie-in referee's diairi'et'er'there'arith.

m any teeming this mven'aen a'sin- Electra-ea lidiiipi'isesat least two layers or cchdiictive coherent particulate metal 1!} faci'a'lfcdndiictive "rel'etieiismp so that jti'i'eniajoi' eegwe eiateriei lens inust thiebgh 'aiiiiegear'uemate layer er more i ennietai; saeiifas 'mekei, winen is more rugged am c-1a the metre-me easement in the elefitrolyticceli iii timer; it is used.

Having say iir'ivntibn, I claim:

seasineesae iiietal-iic negative electgeu -fer storage beetraser the alkaline eieetrcly'te "type eemiiii'sihe layer of -i'e la'- may 'mgmy eieetgeiyueaiiy'aeuve negative porous parti'uiatesbra'yiieposited iiietal enveie'ped by a'nd tlieriii ally'itndccnductitely bonded tofa'n esteem: relatively aeuv porous spray deposited barticiiiate V nickel layer, 'sald' i'iik'i layer imparting the ch racterist cs *0: stability and "durability to seid'eieetreee rendering the "same fesistant to cori' csidn'abd disintegration. M

2. A composl'te'fpoi jasmine ele'ctrc'de "for storage batteries "cdmprising an iririei layer of electrolytically mere save berets particulate cofherent I metal enveloped by thermally and conductively bonded "as an easier porous, less active permeable coherent layer of particulate metal, said exterior layer imparting the characteristics of stability and durabllity to said electrode by rendering the same-ram to corrosion and disintegration.

u 3. A composite porous metallic negative electrode for storage batteries 01' the alkaline electrolyte type comprising an inner layer of relatively highly electrolytically active negative porou's particulate spray deposited metal enveloped by and thermally and conductively bonded to an exterior relatively less active porous layer of particulate spray deposited nickel, said outer layer comprising a deposit of particles of a size generally greater than 10 microns in diamet'er'fofming a grid-like surface characteristic dad a '8- posit of particles of a size generally less m 10 microns in diameter as a iilllng' for said gfld libe surface characteristic;

4. A composite porous metallic memes 6! storage batteries of the alkaline electrolyte type comprising a relatively highly electrolyticallytive in'ne'r body of porous molten spray particulate cadmium enveloped by and thermal! and conductively bonded to an exterior relatively less active porous layer 0'! spray deposited particulate nickel, such exterior layer imparting "8 characteristics or stability and durability to laid electrode by rendering the sameresistafltw 00frosion and disintegration; v

5. 'A composite "poreus metallic electrode in storage batteries as defined ih'clailn '4 in which the molten spray "deposited particulate said relatively highly electrolytically eetlveatner body is iron. 7 v

6. A composite porous metallic eleetrede for storage batteries "as defined in claim 4 in mm the rliolten spray ee esitea psi-amine "6! said relatively highly electrolytically active 1m! body is zinc.

7. A composite poi-oils metflllic eieetrede tor storage batteries as "defined in claim 4 in which "the molten spray eposited particulate meters! 's'a'i'd relatively iii'gmy eieetreiyueauy eeme mm may issilver. V

a. A composite po'r'ous metaliiceiecrroae-m storage setterieser the amaiine eieetreiywtype comprising ar'e'latively highly electrolytically 5ttive i'illlrbbdy dfbOi'lisilbltfi splay dipim "teammate mete; eiivempea By and 'tliillibliy "and conductively Bot-idea 'rlflm less active pereus layer or spra 'uepesi" ten perti'ciilate nickel; the particulate iit'e'til or eedy beingene s'elctel ir'blh theagreup will?! of cadmium, area, and "snverg m exterior layer imparting the enermrm'ei stability aria durability to said eieetreaeby rmderi'n'g the same resistant to eeiroeieaaaa 

1. A COMPOSITE POROUS METALLIC NEGATIVE ELECTRODE FOR STORAGE BATTERIES OF THE ALKALINE ELECTROLYTE TYPE COMPRISING AN INNER LAYER OF RELATIVELY HIGHLY ELECTROLYTICALLY ACTIVE NEGATIVE POROUS PARTICULATE SPRAY DEPOSITED METAL ENVELOPED BY AND THERMALLY AND CONDUCTIVELY BONDED TO AN EXTERIOR RELATIVELY LESS ACTIVE POROUS SPRAY DEPOSITED PARTICULATE NICKEL LAYER, SAID NICKEL LAYER IMPARTING THE CHARACTERISTICS OF STABILITY AND DURABILITY TO SAID ELECTRODE BY RENDERING THE SAME RESISTANT TO CORRROSION AND DISINTEGRATION. 